Container for shipping a product and method of constructing the same

ABSTRACT

A container for packaging a product is provided. The container is formed from a continuous blank of sheet material having an internal surface and an opposing external surface. The container includes a top panel having a top edge, a bottom edge, and opposing side edges. The container further includes a hinge panel connected to the bottom edge of the top panel along a first fold line, a rear panel connected to the hinge panel along a second fold line and connected to the top panel, and a first adhesive coating applied on the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge defining a perimeter of a compartment for receiving a product. Moreover, after the product is placed in the compartment, the top panel and the rear panel are folded about the hinge panel such that at least a portion of the internal surfaces of the top and rear panels are attached to one another. A method of constructing the same is also provided.

BACKGROUND OF THE INVENTION

This invention relates generally to containers and, more particularly, to a container for shipping a product stored within the container, and a method of constructing the container.

Containers are oftentimes used to store, display, and/or transport a product or a plurality of products. For example, a distributor of media products, such as compact discs (CDs) and digital video discs (DVDs), may have to place their products within a container for shipment to consumers. At least some known containers are fabricated from rigid cardboard, filled with a digital media product, and closed for transportation to a home or retail store. Some known cardboard containers are constructed such that the cardboard is wrapped around the contents of the container and then sealed to retain the contents within the container. The cost to construct and transport rigid cardboard containers is ever increasing, particularly when the cardboard container is shipped through the mail or through a delivery service. Thus, a flexible container for housing products such as digital media products that can easily be produced and that facilitates reducing the expense of transporting the products is needed.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, a container for packaging a product is provided. The container is formed from a continuous blank of sheet material having an internal surface and an opposing external surface. The container includes a top panel having a top edge, a bottom edge, and opposing side edges. The container further includes a hinge panel connected to the bottom edge of the top panel along a first fold line, a rear panel connected to the hinge panel along a second fold line and connected to the top panel, and a first adhesive coating applied on the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge defining a perimeter of a compartment for receiving a product. Moreover, after the product is placed in the compartment, the top panel and the rear panel are folded about the hinge panel such that at least a portion of the internal surfaces of the top and rear panels are attached to one another.

In a further aspect, a blank of sheet material for constructing a container used for shipping a product is provided. The blank has an internal surface and an opposing external surface. The blank includes a top panel having a top edge, a bottom edge, and opposing side edges, a hinge panel connected to the bottom edge of the top panel along a first fold line, and a rear panel connected to the hinge panel along a second fold line and connected to the top panel, wherein the rear panel includes a first adhesive coating applied thereto on the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge to a perimeter of a compartment for receiving the product.

In a further aspect, a method of constructing a container used for shipping a product is provided. The container is formed from a continuous blank of sheet material having an internal surface and an opposing external surface. The blank includes a top panel having a top edge, a bottom edge, and opposing side edges. The blank further includes a hinge panel connected to the bottom edge of the top panel along a first fold line, and a rear panel connected to the hinge panel along a second fold line and connected to the top panel. The method includes providing the blank of sheet material, applying a first adhesive coating to a portion of the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge defining a perimeter of a compartment for receiving the product, placing the product within the compartment of the container, folding the top panel towards the interior surface of the rear panel along the hinge panel, and applying at least one of heat and pressure in the area of the coating to seal the container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a blank of sheet material for constructing a container according to one embodiment.

FIG. 2 is a perspective view of a container partially constructed from the blank shown in FIG. 1.

FIG. 3 is a perspective view of a container constructed from the blank shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is described below in reference to its application in connection with and operation of a container for mailing digital media products (e.g., compact discs (CDs), digital video discs (DVDs), a minidisc, a digital video, a video game, a record, etc.). However, it will be apparent to those skilled in the art and guided by the teachings herein provided that the invention is likewise applicable to any suitable storage and/or container including, without limitation, a carton, a tray or a box.

In one embodiment, the container is fabricated from a paperboard material. The container, however, may be fabricated using any suitable material, and therefore is not limited to a specific type of material. In alternative embodiments, the container is fabricated using cardboard, corrugated board, plastic and/or any suitable material known to those skilled in the art and guided by the teachings herein provided. The container may have any suitable size, shape and/or configuration, i.e. number of sides, whether such sizes, shapes and/or configurations are described and/or illustrated herein. For example, in one embodiment, the container includes a shape that provides functionality, such as a shape that facilitates transporting the container and/or a shape that facilitates stacking and/or arrangement of a plurality of containers.

FIGS. 1-3 illustrate the construction of one embodiment of a container. Specifically, FIG. 1 illustrates a plan view of one embodiment of a blank of sheet material designated in its entirety by element reference number 10. FIG. 2 is a perspective view of a container partially constructed designated in its entirety by element reference numeral 12 constructed from blank 10 shown in FIG. 1. FIG. 3 is a perspective view of container 12 in the constructed configuration.

Referring to FIG. 1, blank 10 is made of flexible paperboard material including a first corrugated surface or internal surface 14 and an opposing second surface or external surface 16. In one embodiment, first surface 14 is blank or void of any marking, such as a graphic and/or other printing, and second surface 16 includes at least one print screen thereon. The print screen includes any suitable markings including, without limitation, indicia that communicates the product, a manufacturer of the product and/or a seller of the product. In a particular embodiment, the print screen is positioned on one or more panels (as described in greater detail below) on second surface 16 of blank 10 and corresponds to a visible surface, such as an exterior surface or a second surface, of constructed container 12.

Blank 10 includes a first edge 30, an opposing second edge, 32, and two substantially parallel edges 34 and 36 extending therebetween. Blank 10 has a width W₁ defined between edges 30 and 32, and a length L₁ defined between edges 34 and 36. Moreover, blank 10 includes a first panel or top panel 18, an opposing second panel or rear panel 20, and a folding panel or hinge panel 22 extending therebetween. First panel 18 is hingeably coupled to second panel 20 along a fold line 24 extending partially between edges 30 and 32. In one embodiment, fold line 24 includes a hinge line and/or a line of separation, such as a die cut, defined along a portion of fold line 24. It is apparent to those skilled in the art and guided by the teachings herein provided that fold line 24, as well as other fold lines described herein, may include any suitable line or lines of weakening.

In one embodiment, first and second panels 18 and 20 have a substantially similar shape. Specifically, first and second panels 18 and 20 have a substantially square shape. Moreover, first panel 18 has a length L₃ defined between edge 34 and fold line 24, and second panel 20 has a length L₂ defined between edge 36 and fold line 24. In one embodiment, length L₂ and length L₃ are substantially equal, and are approximately half the length of L₁. In an alternative embodiment, first and second panels 18 and 20 may have any suitable shape to facilitate forming container 12, and length L₂ and length L₃ have different lengths.

In one embodiment, folding panel 22 is defined by two arcuate score lines 26 and 28. Score lines 26 and 28 intersect forming at least two intersections 38 and 40 defined along fold line 24. In an alternative embodiment, score lines 26 and 28 intersect forming more than two intersections. In an alternative embodiment, blank 10 does not include folding panel 22 and score lines 26 and 28; rather, blank 10 includes a single transverse score line (not shown) extending between edges 30 and 32.

Moreover, blank 10 includes a display window 42 defined within a portion of panel 20. In one embodiment, display window 42 forms an opening within panel 20 and is substantially square in shape. Specifically, display window 42 includes a first edge 44, an opposing second edge 46, and two substantially parallel edges 48 and 50 extending therebetween. In an alternative embodiment, display window 42 has any suitable shape. In a further alternative embodiment, blank 10 does not include display window 42. In a further alternative embodiment, both first and second panels 18 and 20 include display window 42. In one embodiment, a substantially transparent plastic material (not shown) is coupled to surface 14 such that the plastic material is adjacent to at least a portion of display window 42.

First surface 14 of first panel 18 includes a coating 54 that is applied to first panel 18, and first surface 14 of second panel 20 includes a coating 56 that is applied to second panel 20. Coatings 54 and 56 are configured to facilitate coupling first and second panels 18 and 20 together. In one embodiment, coatings 54 and 56 are co-adhesive coatings. In an alternative embodiment, coatings 54 and 56 are heat activated sealants and/or any suitable coating that facilitates the coupling of first and second panels 18 and 20.

In one embodiment, coating 54 is applied to the entire first surface 14 of first panel 18, and coating 56 is applied to first surface 14 of second panel 20 in a U-shape. Coating 56 includes a first portion 58, an opposing second portion 60, and a third portion 62 extending therebetween. Specifically, first portion 58 of coating 56 is applied parallel and adjacent to a portion of edge 30, second portion 60 of coating 56 is applied parallel and adjacent to a portion of edge 32, and third portion 62 of coating 56 is applied parallel and adjacent to a portion of edge 36 defining a perimeter for a compartment. Moreover, coating 56 is applied outward of display window 42. In an alternative embodiment, coating 54 is applied to only a portion of first surface 14 of first panel 18, and coating 56 is applied to first surface 14 of second panel 20 in any suitable shape that facilitates coupling first surface 14 of first panel 18 to first surface of second panel 20 while providing space for a product to be placed between first panel 18 and second panel 20 for sealing the product within container 12.

FIG. 2 shows container 12 in a partially constructed open configuration 61. Container 12 is constructed from blank 10. Container 12 is flexible and is configured to receive contents 63, such as, but not limited to, a compact disc (CD), a digital video disc or a digital versatile disc (DVD), a minidisc, a digital video, a video game, and/or a record.

In use, coatings 54 and 56 are applied to first panels 18 and 20, respectively, and contents 63 are positioned adjacent first surface 14 of first panel 18. In one embodiment, contents 63 are positioned such that a portion of contents 63 is adjacent score line 26 and/or folding panel 22. Moreover, in one embodiment, contents 63 are positioned adjacent first surface 14 of first panel 18 with a high-speed automatic system.

FIG. 3 shows container 12 in a fully constructed closed configuration 64. In use, after contents 63 are positioned adjacent first panel 18, second panel 20 is folded along score lines 26 and 28 towards first surface 14 forming folding panel 22. Second panel 20 is coupled to first panel 18 by coupling a portion of coating 54 to a portion of coating 56 using a heat sealing tool. Specifically, the heat sealing tool heats coatings 54 and 56 activating the adhesive and/or sealant properties of coatings 54 and 56. Once the adhesive properties are activated, second surfaces 16 of first panel 18 and second panel 20 are compressed together to continuously seal first, second, and third portions 58, 60, and 62 of coating 56 to coating 54 closing container 12 and forming the compartment configured to receive contents 63 therein. As shown in FIG. 3, an imprint 66 on second surface 16 of second panel 20 is generally shown in the location of the heat sealing on first surface 14 of second panel 20. The heat sealing tool provides an efficient high-speed means to construct container 12 from open configuration 61 to closed configuration 64.

In an alternative embodiment, coatings 54 and 56 do not require heat to activate the adhesive and/or sealant properties of coatings 54 and 56. Moreover, in the alternative embodiment, container 12 is rotated from open configuration 61 to closed configuration 64 using any suitable mechanism, and first panel 18 and second panel 20 are coupled together solely by applying pressure to the second surfaces 16 of first panel 18 and second panel 20 to seal first, second, and third portions 58, 60, and 62.

Once container 12 is in closed configuration 64, coating 54 substantially prevents contents 63 of container 12 from shifting within container 12, and contents 63 are visible through display window 42. Moreover, to enhance security against theft, coatings 54 and 56 provide a tamper-resistant measure and a tamper-evident measure for container 12 in closed configuration 64.

The above-described container and method of constructing the container provides a container that is easily constructed from a flexible unitary blank of paperboard and transports contents such as digital media. Moreover, the container includes an opening formed within a portion of the container such that contents of the container are visible when the container is in a constructed configuration. As a result, consumers can transport contents within a flexible container while viewing the contents of the closed container.

Exemplary embodiments of a container have been described above in detail. The apparatus is not limited to the specific embodiments described herein, but rather, components of the container and/or steps of the method may be utilized independently and separately from other components and/or steps described herein. Further, the described apparatus components and/or method steps can also be defined in, or used in combination with, other apparatus and/or methods, and are not limited to practice with only the apparatus and method as described herein.

While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims. 

1. A container for packaging a product, the container formed from a continuous blank of sheet material having an internal surface and an opposing external surface, the container comprising: a top panel having a top edge, a bottom edge, and opposing side edges; a hinge panel connected to the bottom edge of the top panel along a first fold line; a rear panel connected to the hinge panel along a second fold line and connected to the top panel; and a first adhesive coating applied on the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge defining a perimeter of a compartment for receiving a product, wherein after the product is placed in the compartment, the top panel and the rear panel are folded about the hinge panel such that at least a portion of the internal surfaces of the top and rear panels are attached to one another.
 2. A container in accordance with claim 1 wherein a second adhesive coating is applied to at least a portion of the internal surface of the top panel, and wherein at least one of the first adhesive coating and the second adhesive coating is a co-adhesive coating.
 3. A container in accordance with claim 1 wherein the first adhesive coating is applied in a U-shape to the internal surface of the rear panel.
 4. A container in accordance with claim 1 wherein at least one of the top panel and the rear panel comprises a display window for viewing the product included within the container.
 5. A container in accordance with claim 1 wherein at least one of the first and second fold lines is a curved score line.
 6. A container in accordance with claim 1 wherein the blank comprises continuous flexible paperboard.
 7. A container in accordance with claim 1 wherein the internal surface is scored.
 8. A blank of sheet material for constructing a container used for shipping a product, the blank having an internal surface and an opposing external surface, said blank comprising: a top panel having a top edge, a bottom edge, and opposing side edges; a hinge panel connected to the bottom edge of the top panel along a first fold line; and a rear panel connected to the hinge panel along a second fold line and connected to the top panel, wherein the rear panel includes a first adhesive coating applied thereto on the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge to a perimeter of a compartment for receiving the product.
 9. A blank in accordance with claim 8 wherein the top panel includes a second adhesive coating applied to at least a portion of the internal surface of the top panel.
 10. A blank in accordance with claim 9 wherein at least one of the first adhesive coating and the second adhesive coating is a co-adhesive coating.
 11. A blank in accordance with claim 8 wherein the first adhesive coating is applied in a U-shape to the internal surface of the rear panel.
 12. A blank in accordance with claim 8 wherein at least one of the top panel and the rear panel comprises a display window for viewing the product included within the container.
 13. A blank in accordance with claim 8 wherein at least one of the first and second fold lines is a curved score line.
 14. A blank in accordance with claim 8 further comprising continuous flexible paperboard.
 15. A container in accordance with claim 8 wherein the internal surface is scored.
 16. A method of constructing a container used for shipping a product, the container is formed from a continuous blank of sheet material having an internal surface and an opposing external surface, the blank further includes a top panel having a top edge, a bottom edge, and opposing side edges, the blank further includes a hinge panel connected to the bottom edge of the top panel along a first fold line, and a rear panel connected to the hinge panel along a second fold line and connected to the top panel, said method comprising: providing the blank of sheet material; applying a first adhesive coating to a portion of the internal surface of the rear panel adjacent to the opposing side edges and the bottom edge defining a perimeter of a compartment for receiving the product; placing the product within the compartment of the container; folding the top panel towards the interior surface of the rear panel along the hinge panel; and applying at least one of heat and pressure in the area of the coating to seal the container.
 17. A method in accordance with claim 16 further comprising applying a second adhesive coating to at least a portion of the internal surface of the top panel.
 18. A method in accordance with claim 17 further comprising compressing the first adhesive coating and the second adhesive coating together using heat seal tooling to close the container.
 19. A method in accordance with claim 16 wherein at least one of the top panel and the rear panel has a display window, said method further comprising coupling a transparent plastic material to the internal surface adjacent at least a portion of the display window.
 20. A method in accordance with claim 16 further comprising folding the rear panel towards the interior surface of the top panel along the hinge panel. 